Display device and method of manufacturing the same

ABSTRACT

A display device includes a display panel, a first film, and a second film. The display panel includes a light emitter to emit light including display information, a first surface, and a second surface opposite to the first surface. The light passes through a second surface. The first film is on the first surface of the display panel. The second film is on the second surface of the display panel. The display panel includes a side surface that connects the first surface and the second surface. A side surface of the second film protrudes outwardly more than a side surface of the first film with respect to the side surface of the display panel. The side surface of the second film is inclined at an angle greater than about 90 degrees with respect to the second surface.

CROSS-REFERENCE TO RELATED APPLICATION

Korean Patent Application No. 10-2016-0072736, filed on Jun. 10, 2016,and entitled, “Display Device and Method of Manufacturing the Same,” isincorporated by reference herein in its entirety.

BACKGROUND 1. Field

One or more embodiments described herein relate to a display device anda method for manufacturing a display device.

2. Description of the Related Art

Each pixel of an organic light emitting display device may include acircuit for controlling an organic light emitting diode. The circuitincludes a control transistor, a driving transistor, and a storagecapacitor. The organic light emitting diode includes an organic lightemitting layer between anode and cathode electrodes. The organic lightemitting diode emits light when a voltage greater than a thresholdvoltage of the organic light emitting layer is applied between the anodeand cathode electrodes.

SUMMARY

In accordance with one or more embodiments, a display device includes adisplay panel including a light emitter to emit light including displayinformation, a first surface, and a second surface opposite to the firstsurface, the light to pass through a second surface; a first film on thefirst surface of the display panel; and a second film on the secondsurface of the display panel, wherein the display panel includes a sidesurface that connects the first surface and the second surface, whereina side surface of the second film protrudes outwardly more than a sidesurface of the first film with respect to the side surface of thedisplay panel, and wherein the side surface of the second film isinclined at an angle greater than about 90 degrees with respect to thesecond surface.

The side surface of the display panel may protrude outwardly more thanthe side surface of the first film. The side surface of the displaypanel and the side surface of the first film may be inclined at an angleless than about 90 degrees with respect to the second surface. Aninclined angle of the side surface of the display panel and the secondsurface may be equal to or less than an inclined angle of the sidesurface of the first film and the second surface.

The display device may include a first pressure sensitive adhesive thatadheres the first film to the first surface of the display panel; and asecond pressure sensitive adhesive that adheres the second film to thesecond surface of the display panel. The first film may support thedisplay panel and the second film may be a polarizing film.

The display device may include a protective film that protects thesecond film; a lower support film under the first film; and a thirdpressure sensitive adhesive that adheres the lower support film to thefirst film. A haze area may be in an upper surface of the second filmadjacent to the side surface of the second film, and the haze area mayhave a width of from about 1 micrometer to about 100 micrometers. Thelight emitter may include an organic light emitter.

In accordance with one or more other embodiments, a display deviceincludes a display panel including a light emitter to emit lightincluding display information, a first surface, and a second surfaceopposite to the first surface, the light to pass through the secondsurface; a support film on the first surface of the display panel; and apolarizing film on the second surface of the display panel, wherein across-section corresponding to a side surface of the polarizing film, aside surface of the display panel, and a side surface of the supportfilm is inclined in a direction away from a center of the display devicewith respect to a normal line direction of the second surface thatsequentially penetrates through the support film, the display panel, andthe polarizing film.

The cross-section may include a first cross-section corresponding to theside surface of the support film and the side surface of the displaypanel; and a second cross-section corresponding to the side surface ofthe polarizing film, wherein an inclined angle of the firstcross-section is different from an inclined angle of the secondcross-section. The inclined angle of the second cross-section may begreater than the inclined angle of the first cross-section.

The display device may include a first pressure sensitive adhesive thatadheres the support film to the first surface of the display panel; anda second pressure sensitive adhesive that adheres the polarizing film tothe second surface of the display panel. The display device may includea protective film that protects the polarizing film, a lower supportfilm under the support film, and a third pressure sensitive adhesivethat adheres the lower support film to the support film. A haze area maybe in an upper surface of the polarizing film adjacent to the sidesurface of the polarizing film, and the haze area may have a width offrom about 1 micrometer to about 100 micrometers. The light emitter mayinclude an organic light emitter.

In accordance with one or more other embodiments, a method formanufacturing a display device forming a mother substrate including aplurality of display units, each of the display units including aplurality of light emitters to emit light including display information;attaching a first mother film and a second mother film to a firstsurface of the mother substrate and a second surface of the mothersubstrate, which is opposite to the first surface, respectively, to forma display mother substrate; and irradiating a laser beam on the displaymother substrate from the first mother film to cut the display mothersubstrate in to the light emitters to form the display device, whereinthe light passes through the second surface. The laser beam may beirradiated in a multi-pass process.

Irradiating the laser beam may include irradiating the laser beam with afirst intensity; and irradiating the laser beam with a second intensityless than the first intensity. Irradiating the laser beam with the firstintensity may be performed in a first multi-pass process, andirradiating the laser beam with the second intensity may be performed ina second multi-pass process, the second multi-pass process greater thanthe first multi-pass process. The first mother film and the mothersubstrate may be cut by irradiating the laser beam with the firstintensity, and the second mother film may be cut by irradiating thelaser beam with the second intensity. The first mother film may be asupport film and the second mother film may be a polarizing film. Thelaser beam may be at least one of an ultraviolet laser beam or a carbondioxide laser beam.

BRIEF DESCRIPTION OF THE DRAWINGS

Features will become apparent to those of skill in the art by describingin detail exemplary embodiments with reference to the attached drawingsin which:

FIG. 1 illustrates an embodiment of a display device;

FIG. 2 illustrates a view along section lines I-I′ and II-IP in FIG. 1;

FIG. 3 illustrates another embodiment of a display device;

FIG. 4 illustrates another embodiment of a display device;

FIG. 5 illustrates another embodiment of a display device;

FIG. 6 illustrates another embodiment of a display device;

FIG. 7 illustrates another embodiment of a display device;

FIG. 8 illustrates another embodiment of a display device;

FIG. 9 illustrates an embodiment of a display panel;

FIG. 10 illustrates an embodiment of a mother substrate with a displayunit;

FIGS. 11A to 11D illustrate various stages in an embodiment of a methodfor manufacturing a display device;

FIGS. 12A to 12D illustrate an embodiment of a cutting process;

FIGS. 13A to 13C illustrate another embodiment of a cutting process;

FIGS. 14A and 14B illustrate another embodiment of a cutting process;

FIGS. 15A and 15B illustrate another embodiment of a cutting process;

FIGS. 16A and 16B illustrate an embodiment obtained by irradiating alaser beam two times; and

FIGS. 17A and 17B illustrate another embodiment obtained by irradiatinga laser beam two times.

DETAILED DESCRIPTION

The following description with reference to the accompanying drawings isprovided to assist in a comprehensive understanding of variousembodiments of the present disclosure as defined by the claims and theirequivalents. It includes various specific details to assist in thatunderstanding but these are to be regarded as merely exemplary.Accordingly, those of ordinary skill in the art will recognize thatvarious changes and modifications of the various embodiments describedherein can be made without departing from the scope and spirit of thepresent disclosure. In addition, descriptions of well-known functionsand constructions may be omitted for clarity and conciseness.

When an element is referred to as being “connected” or “coupled” toanother element, it can be directly connected or coupled to the anotherelement or be indirectly connected or coupled to the another elementwith one or more intervening elements interposed therebetween. Inaddition, when an element is referred to as “including” a component,this indicates that the element may further include another componentinstead of excluding another component unless there is differentdisclosure.

FIG. 1 illustrates an embodiment of a display device 1000, and FIG. 2 isa cross-sectional view taken along lines I-I′ and II-II′ in FIG. 1.Referring to FIG. 1, the display device 1000 includes a display area DAand a non-display area NA distinguished from the display area DA whenviewed in a plan view. The display area DA displays an image, while thenon-display area NA does not display an image. The non-display area NAmay be adjacent to one side of the display area DA. In anotherembodiment, the non-display area NA may be adjacent to at least one ofthe other sides of the display area DA and/or more than one side of thedisplay area.

The non-display area NA includes a pad area PDA which may be connectedto a flexible printed circuit board. The display device 1000 may receivesignals to drive the display device 1000 through the pad area PDA.

A haze area HA is at an edge of the display area DA. In the presentexemplary embodiment, the haze area HA is at one or more sides differentfrom the side adjacent to the non display area NA. When the non-displayarea NA is adjacent to another side, the position of the haze area HAmay be changed accordingly.

Referring to FIG. 2, the display device 1000 includes a display panel100, a first film 200, and a second film 300 stacked along a firstdirection DR1. The display panel 100 includes a display element emittinglight including display information. The display element may be, but isnot limited to, an organic light emitting element, a liquid crystaldisplay element, a plasma display element, an electrophoretic displayelement, a microelectromechanical system display element, or anelectrowetting display element. An organic light emitting element willbe described below as a representative example.

The display panel 100 includes a second surface 102 opposite to a firstsurface 101. The display panel 100 outputs light emitted by the displayelement through the second surface 102. The first film 200 is on thefirst surface 101 of the display panel 100. The second film 300 is onthe second surface 102 of the display panel 100. The display device 1000may further include a first pressure sensitive adhesive 400 between thefirst film 200 and the display panel 100.

The first film 200 may be, but is not limited to, a support film tosupport and protect the display panel 100. The first film 200 mayinclude polyethylene terephthalate (PET), polyethylene naphthalate(PEN), polypropylene (PP), polycarbonate (PC), polystyrene (PS),polysulfone (PSul), polyethylene (PE), polyphthalamide (PPA),polyethersulfone (PES), polyarylate (PAR), polycarbonate oxide (PCO), ormodified polythenylene oxide (MPPO). In the present exemplaryembodiment, the first film 200 includes polyethylene terephthalate(PET).

The second film 300 may include a polarizing film to block externallight incident thereto. The polarizing film may include a linearpolarizing layer and a λ/4 retardation layer. The linear polarizinglayer may be on, for example, the λ/4 retardation layer. External lightsequentially passing through the linear polarizing layer and the λ/4retardation layer is reflected by a lower portion (e.g., a cathode ofthe display panel 100) of the polarizing film. Then, the external lightis suppressed since the external light does not pass through the linearpolarizing layer after passing through the λ/4 retardation layer.

The first pressure sensitive adhesive 400 adheres the first film 200 tothe first surface 101. The first pressure sensitive adhesive 400includes, for example, an urethane-based material, an acrylic-basedmaterial, or a silicon-based material.

The display panel 100 further includes a side surface 103 connecting thefirst surface 101 and the second surface 102. A side surface 303 of thesecond film 300 may protrude outwardly along a second direction DR2 thana side surface 203 of the first film 200 and the side surface 103 of thedisplay panel 100. In addition, the side surface 103 of the displaypanel 100 may protrude outwardly along the second direction DR2 morethan the side surface 203 of the first film 200.

Accordingly, each of the side surface 203 of the first film 200, theside surface 103 of the display panel 100, and the side surface 303 ofthe second film 300 may be inclined at a predetermined angle and, forexample, aligned to form a continuous slanted side surface. The anglebetween the side surface 303 of the second film 300 and the secondsurface 102 may be referred to as a first inclination angle θ1. Thefirst inclination angle θ1 may be greater than a predetermined angle,e.g., about 90 degrees.

An angle between the side surface 103 of the display panel 100 and thesecond surface 102 may be referred to as a second inclination angle θ1.An angle between an extension line of the side surface 203 of the firstfilm 200 and the second surface 102 may be referred to as a thirdinclination angle θ3. In one embodiment, the second and thirdinclination angles θ1 and θ3 may be less than a predetermined angle(e.g., less than about 90 degrees). The second and third inclinationangles θ1 and θ3 may be equal or different.

A first burr BU1 is on a lower surface 201 of the first film 200 andadjacent to the side surface 203 of the first film 200. A second burrBU2 is on an upper surface 301 of the second film 300 and adjacent tothe side surface 303 of the second film 300. In one embodiment, thefirst and second burrs BU1 and BU2 may have different sizes, e.g., thesecond burr BU2 may be smaller than the first burr BU1.

A yellow area YA may be in the lower surface 201 of the first film 200and the upper surface 301 of the second film 300 and adjacent to thefirst and second burrs BU1 and BU2. FIG. 2 shows only the yellow area YAin the upper surface 301 of the second film 300 for illustrativepurposes.

The haze area HA may correspond to an area which includes the area inwhich the second burr BU2 is formed and the yellow area YA. As anexample, the haze area HA has a width of from about 1 micrometers toabout 100 micrometers.

When a direction vertical to the first and second surfaces 101 and 102of the display panel 100 and toward the second surface 102 from thefirst surface 101 is a first direction DR1, a direction vertical to thefirst direction DR1 may be a second direction DR2. The width of the hazearea HA may correspond to a width in the second direction DR2 of thehaze area HA when the display panel 100 is cut along a directionvertical to two parallel sides.

FIG. 3 is a cross-sectional view of another embodiment of a displaydevice 1001 which further includes a second pressure sensitive adhesive500. The second pressure sensitive adhesive 500 is between the secondsurface 102 of the display panel 100 and the second film 300 to adherethe second film 300 to the second surface 102. The second pressuresensitive adhesive 500 includes, for example, an urethane-basedmaterial, an acryl-based material, or a silicon-based material.

The side surface 203 of the first film 200, the side surface 103 of thedisplay panel 100, and the side surface 303 of the second film 300 maycorrespond to a cross-section ST of the display device 100. Thecross-section ST may be inclined with respect to a normal linedirection, e.g., the first direction DR1, of the second surface 102,which sequentially penetrates through the first film 200, the displaypanel 100, and the second film 300.

The cross-section ST is inclined outwardly away from a center of thedisplay device 1001 with respect to the first direction DR1. FIG. 3shows only a left cross-section ST of the display device 1001, but aright cross-section may be symmetrical with the left cross-section STrelative to the first direction DR1. For example, when the inclineddirection of the left cross-section ST relative to the first directionDR1 is a third direction DR3, the right cross-section is inclined in adirection symmetrical with the third direction DR3 relative to the firstdirection DR1.

FIG. 4 is a cross-sectional view of another embodiment of a displaydevice 1002 which includes a first cross-section ST1 and a secondcross-section ST2 having a slope different from a slope of thefirst-cross-section ST1. The first cross-section ST1 corresponds to theside surface 203 of the first film 200 and the side surface 103 of thedisplay panel 100L. The second cross-section ST2 corresponds to the sidesurface 303 of the second film 300.

For example, the first and second cross-sections ST1 and ST2 areinclined outwardly to be far away from the center of the display device1002 with respect to the first direction DR1. The first cross-sectionST1 inclined with respect to the first direction DR1 may be referred toas a fourth direction DR4. The second cross-section ST2 inclined withrespect to the first direction DR1 may be referred to as a fifthdirection DR5.

In the present exemplary embodiment, the angle between the firstdirection DR1 and the fourth direction DR4 may referred to as a fourthinclination angle θ4. The angle between the first direction DR1 and thefifth direction DR5 may be referred to as a fifth inclination angle θ5.The fourth and fifth angles θ4 and θ5 may be different from each other.For example, the fourth inclination angle θ4 may be greater than thefifth inclination angle θ5.

FIG. 4 shows only left first and second cross-sections ST1 and ST2 ofthe display device 1002, but right first and second cross-sections maybe symmetrical with the left first and second cross-sections ST1 and ST2relative to the first direction DR1. For example, the right first andsecond cross-sections are inclined to directions respectivelysymmetrical with the fourth and fifth directions DR4 and DR5 withrespect to the first direction DR1.

FIG. 5 is a cross-sectional view of another embodiment of a displaydevice 1003 which further includes a protective film 600 protecting thesecond film 300, a lower support film 700 disposed under the first film200, and a third pressure sensitive adhesive 800 disposed between thelower support film 700 and the first film 200.

The protective film 600 is on the second film 200 to protect the secondfilm 300. The protective film 600 includes, for example, polyethyleneterephthalate (PET), polyethylene naphthalate (PEN), polypropylene (PP),polycarbonate (PC), polystyrene (PS), polysulfone (PSul), polyethylene(PE), polyphthalamide (PPA), polyethersulfone (PES), polyarylate (PAR),polycarbonate oxide (PCO), or modified polythenylene oxide (MPPO).

The lower support film 700 is under the first film 200 to protect andsupport internal components of the display device 103 at an outermostposition of the display device 103. The lower support film 700 includes,for example, polyethylene terephthalate (PET), polyethylene naphthalate(PEN), polypropylene (PP), polycarbonate (PC), polystyrene (PS),polysulfone (PSul), polyethylene (PE), polyphthalamide (PPA),polyethersulfone (PES), polyarylate (PAR), polycarbonate oxide (PCO), ormodified polythenylene oxide (MPPO).

The third pressure sensitive adhesive 800 adheres the lower support film700 to the first film 200.

A cross-section ST3 of the display device 1003 corresponds to a sidesurface of the lower support film 700, a side surface 203 of the firstfilm 200, a side surface 103 of the display panel 100, a side surface303 of the second film, and a side surface 603 of the protective film600. The cross-section ST3 is inclined with respect to a normal linedirection, e.g., the first direction DR1, of the second surface 102,which sequentially penetrates through the first film 200, the displaypanel 100, and the second film 300.

The cross-section ST3 is inclined outwardly away from a center of thedisplay device 1003 with respect to the first direction DR1. Forexample, the cross-section ST3 is inclined in the third direction DR3outwardly inclined with respect to the first direction DR1.

Accordingly, the side surface 303 of the second film 300 and the sidesurface 603 of the protective film 600 protrude outwardly more than theside surface 203 of the first film 200 with respect to the side surface103 of the display panel 100. In addition, the side surface 103 of thedisplay panel 100 protrudes outwardly more than the side surface 203 ofthe first film 200 and a side surface 703 of the lower support film 700.

A first burr BU1 may be on a lower surface 701 of the lower support film700 and adjacent to the side surface 703 of the lower support film 700.A second burr BU2 may be on an upper surface 601 of the protective film600 and adjacent to the side surface 603 of the protective film 600. Thefirst and second burrs BU1 and BU2 may have different sizes, e.g., thesecond burr BU2 may be smaller than the first burr BU1.

FIG. 6 is a cross-sectional view of an other embodiment of a displaydevice 1004 which includes a first cross-section ST4 and a secondcross-section ST5 having a slope different from a slope of the firstcross-section ST4. The first cross-section ST4 corresponds to the sidesurface 703 of the lower support film 700, the side surface 203 of thefirst film 200, and the side surface 103 of the display panel 100. Thesecond cross-section ST5 corresponds to the side surface 303 of thesecond film 300 and the side surface 603 of the protective film 600.

The first and second cross-sections ST4 and ST5 are inclined outwardlyto be far away from a center of the display device 1004 with respect tothe first direction DR1. A direction in which the first cross-sectionST4 is inclined relative to the first direction DR1 may be referred toas a fourth direction DR4. A direction in which the second cross-sectionST5 is inclined with respect to the first direction DR1 may be referredto as a fifth direction DR5.

The angle between the first direction DR1 and the fourth direction DR4is a fourth inclination angle θ4. The angle between the first directionDR1 and the fifth direction DR5 is a fifth inclination angle θ5. Thefourth and fifth inclination angles θ4 and θ5 may be different, e.g.,the fourth inclination angles θ4 may be greater than the fifthinclination angle θ5.

FIG. 7 is a cross-sectional view of another embodiment of a displaydevice 1005 which may include a first cross-section ST6 and a secondcross-section ST7 having a curvature different from a curvature of thefirst cross-section ST6. The first and second cross-sections ST6 and ST7may be connected to each other. The first cross-section ST6 may includethe side surface 703 of the lower support film 700, the side surface 204of the first film 200, and the side surface 103 of the display panel100. The second cross-section ST7 may include the side surface 303 ofthe second film 300 and the side surface 603 of the protective film 600.

Each of the first and second cross-sections ST6 and ST7 may have ahalf-parabolic shape. The curvature of the first cross-section ST6 maybe different from the curvature of the second cross-section ST7 inanother embodiment.

In one embodiment, the first cross-section ST6 may have a tangent slopedecreasing as the distance from the display panel 100 decreases from thelower support film 700. The second cross-section ST7 may have a tangentslope decreasing as a distance from the protective film 600 decreasesfrom the second film 300.

The side surface 703 of the lower support film 700, the side surface 204of the first film 200, and the side surface 103 of the display panel100, which correspond to the first cross-section ST6, may have differenttangent slopes from each other. For example, a tangent slope of the sidesurface 703 of the lower support film 700 may be greater than a tangentslope of the side surface 204 of the first film 200, and the sidesurface 103 of the display panel 100, and a tangent slope of the sidesurface 203 of the first film 200 may be greater than a tangent slope ofthe side surface 103 of the display panel 100.

The side surface 303 of the second film 300 and the side surface 603 ofthe protective film 600, which corresponds to the second cross-sectionST7, may have different tangent slopes from each other. For example, thetangent slope of the side surface 303 of the second film 300 may begreater than the tangent slope of the side surface 603 of the protectivefilm 600.

The variation in the tangent slope of the first cross-section ST6 may begreater than the variation in the tangent slope of the secondcross-section ST7, e.g., the curvature of the first cross-section ST6may be greater than the curvature of the second cross-section ST7.

FIG. 8 is a cross-sectional view of another embodiment of a displaydevice 1006 which may include at least three cross-sections havingdifferent slopes from each other. Referring to FIG. 8, the displaydevice 1006 may include first, second, third, and fourth cross-sectionsST8, ST9, ST10, and ST11.

The first cross-section ST8 includes the side surface 703 of the lowersupport film 700. The second cross-section ST9 includes the side surface203 of the first film 200 and the side surface 103 of the display panel100. The first cross-section ST8 further includes a side surface 803 ofthe third pressure sensitive adhesive 800. The second cross-section ST9further includes a side surface 403 of the first pressure sensitiveadhesive 400. The third cross-section ST10 includes a side surface 503of the second pressure sensitive adhesive 500. The fourth cross-sectionST11 includes the side surface 303 of second film 300 and the sidesurface 603 of protective film 600.

The angle between an extension line of the first cross-section ST8 andthe second surface 102 may be a sixth inclination angle θ6. The anglebetween the second cross-section ST9 and the second surface 102 may be aseventh inclination angle θ7. The sixth and seventh inclination anglesθ6 and θ7 may be less than a predetermined angle, e.g., about 90degrees. The sixth inclination angle θ6 may be less than the seventhinclination angle θ7.

The angle between the third cross-section ST10 and the second surface102 may be an eighth inclination angle θ8. The angle between anextension line of the fourth cross-section ST11 and the second surface102 may be a ninth inclination angle θ9. The eighth and ninthinclination angles θ8 and θ9 may be less than a predetermined angle,e.g., about 90 degrees. The eighth inclination angle θ8 may be less thanthe ninth inclination angle θ9. In another example, each of the first,second, third, and fourth cross-sections ST8, ST9, ST10, and ST11 mayinclude portions of side surfaces of two layers adjacent to each other.

FIGS. 2 to 8 illustrate cross-sectional structures of variousembodiments of display devices. The cross-sectional structure may bechanged in various ways as long as the side surface 303 of the secondfilm 300 protrudes outwardly more than the side surface 303 of the firstfilm 200 and the side surface 303 of the second film 300 is inclined atan angle greater than a predetermined angle (e.g., about 90 degrees)with respect to the second surface 102.

FIG. 9 is a cross-sectional view of an embodiment of a display panel 100in FIGS. 1 to 8. Referring to FIG. 9, the display panel 100 includes abase substrate 110, a driving layer 120, an organic light emittingelement layer 130, and a sealing layer 140. The base substrate 110provides the first surface 101 of the display panel 100, may be aflexible substrate, and may include a plastic material having superiorthermal resistance and durability, e.g., polyethylene etherphthalate,polyethylene naphthalate, polycarbonate, polyarylate, poly etherimide,polyether sulfone, polyimide, etc. Hereinafter, the base substrate 110includes polyimide as an illustrative case.

The driving layer 120 includes various signal lines, e.g., a scan line,a data line, a power source line, and a light emitting line. The drivinglayer 120 includes a plurality of transistors and a one or morecapacitors. The transistors include a switching transistor and a drivingtransistor which are arranged in every pixel.

FIG. 9 illustrates a driving transistor Qd of the driving layer 120 as arepresentative example. The driving transistor Qd includes an activelayer 211, a gate electrode 213, a source electrode 215, and a drainelectrode 217. The active layer 211 is on the base substrate 110. Thedriving layer 120 further includes a first insulating layer 221 betweenthe active layer 211 and the gate electrode 213. The first insulatinglayer 221 insulates the active layer 211 and the gate electrode 213. Thesource electrode 215 and the drain electrode 217 are on the gateelectrode 213.

The driving layer 120 further includes a second insulating layer 223between the gate electrode 213 and the source electrode 215 and betweenthe gate electrode 213 and the drain electrode 217. The source electrode215 and the drain electrode 217 are connected to the active layer 211respectively through contact holes CH1 and CH2 through the first andsecond insulating layers 221 and 223. The driving layer 120 may furtherinclude a protective layer 230 disposed on the source electrode 215 andthe drain electrode 217.

The structure of the driving transistor Qd may be different from FIG. 9in another embodiment. Also, the positions of the active layer 211, thegate electrode 213, the source electrode 215, and the drain electrode217 may be different in other embodiments, e.g., the gate electrode 213may be on the active layer 211 in FIG. 9 but the gate electrode 213 maybe under the active layer 211.

The switching transistor may have substantially the same structure asthe driving transistor Qd. In an other embodiment, the switching anddriving transistors may have different structures. For instance, anactive layer of the switching transistor may be on a layer differentfrom a layer on which the active layer 211 of the driving transistor Qdis disposed.

The organic light emitting element layer 130 includes an organic lightemitting diode LD. In the present exemplary embodiment, the organiclight emitting diode LD may be a front-surface light-emitting type toemit a light to an upper direction DR3.

The organic light emitting diode LD includes a first electrode AE, anorganic layer OL, and a second electrode CE. The first electrode AE ison the protective layer 230. The first electrode AE is connected to thedrain electrode 217 through a contact hole CH3 through the protectivelayer 230. The first electrode AE is a pixel electrode or a positiveelectrode. The first electrode AE may be a transflective electrode or areflective electrode. When the first electrode AE is a transflectiveelectrode or a reflective electrode, the first electrode AE may include,for example, Ag, Mg, Al, Pt, Pd, Au, Ni. Nd, Ir, Cr, or a mixture ofmetal.

The first electrode AE may have a single-layer structure of a metaloxide or a metal or a multi-layer structure. For example, the firstelectrode AE may have a single-layer structure of ITO, Ag, or a mixtureof metal (e.g., a mixture of Ag and Mg), a double-layer structure ofITO/Mg or ITO/MgF, or a triple-layer structure of ITO/Ag/ITO, but itshould not be limited thereto or thereby.

The organic layer OL includes an organic light emitting layer whichincludes a low molecular weight or high molecular weight organicmaterial. The organic light emitting layer emits light. The organiclayer OL selectively includes a hole transport layer, a hole injectionlayer, an electron transport layer, and/or an electron injection layer.Holes and electrons are injected into the organic light emitting layerfrom the first and second electrodes AE and CE, respectively. Theelectrons are recombined with the holes in the organic light emittinglayer to generate excitons, and the organic light emitting layer emitslight when the excitons transition from an excited state to a groundstate.

The second electrode CE is on the organic light OL. The second electrodeCE is a common electrode or a negative electrode. The second electrodemay be, for example, a transmissive electrode or a transflectiveelectrode. When the second electrode E2 is a transmissive electrode or atransflective electrode, the second electrode E2 may include, forexample, Li, Liq, Ca, LiF/Ca, LiF/Al, Al, Mg, BaF, Ba, Ag, a compoundthereof, or a mixture thereof, e.g., a mixture of Ag and Mg.

The second electrode CE may include an auxiliary electrode, which mayinclude a layer formed by depositing the material to face the organiclight emitting layer and a transparent metal oxide material, e.g.,indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO),indium tin zinc oxide (ITZO), etc., Mo, Ti, or Ag.

The organic light emitting element layer 130 further includes a pixeldefinition layer PDL on the protective layer 230. The pixel definitionlayer PDL overlaps a boundary of the pixel area PA, for example, from aplan view perspective.

The sealing layer is on the organic light emitting element layer 130.The sealing layer 140 provides the upper surface 102 of the displaypanel 100. The sealing layer 143 blocks the organic light emittingelement layer 130 from external moisture and air. The sealing layer 140includes a sealing substrate 141 and a sealing member. The sealingmember is disposed along an edge of the sealing substrate 141 and sealsthe organic light emitting diode LD in cooperation with the sealingsubstrate 141. An inner space 143 defined by the sealing substrate 141and the sealing member is maintained in a vacuum state, but thisarrangement may be different in another embodiment. The inner space 143may be filled with nitrogen (N2) or a filling member including aninsulating material.

Different from the embodiment in FIG. 9, the sealing layer 140 may havea structure in which an organic layer and an inorganic layer are stackedseveral times. The sealing layer 140 may provide the second surface 102of the display panel 100.

FIG. 10 illustrates an embodiment of a mother substrate 2000 including adisplay unit. FIGS. 11A to 11D are cross-sectional views correspondingto an embodiment of a method for manufacturing a display device.

Referring to FIGS. 10 and 11A, the mother substrate 2000 is formed toinclude a plurality of display units DU. The mother substrate 2000further includes a dummy area DM between the display units DU orsurrounding each display unit DU. Each of the display units DU includesdisplay elements formed therein to display an image based on a signalapplied thereto. The display elements may include various types ofdisplay elements. The display units DU may include, for example, theorganic light emitting display element in FIG. 9.

The display elements are not in the dummy area DM. In one embodiment,the display units 1000 may be formed to share one substrate. The dummyarea DM may be removed, for example, at the last stage in themanufacturing process.

FIG. 10 shows six display units DU in one mother substrate, but themother substrate may include a different number of display units DU inanother embodiment depending, for example, on the size of the displayunit DU. When the display units DU are to be flexible, the mothersubstrate 2000 may be formed using a flexible material.

FIG. 11A is a cross-sectional view of an embodiment taken along a linein FIG. 10. Referring to FIG. 11A, three display units DU are arrangedin a second direction DR2 spaced apart from each other. The dummy areaDM is between two adjacent display units DU. The display units DU arecut along a dotted line to form the display panel 100 (e.g., refer toFIGS. 2 to 8), and the dummy area DM is removed after the cuttingprocess. Each of the display units DU emits light including displayinformation. The mother substrate 2000 includes first and secondsurfaces 2001 and 2002 facing each other. The second surface 2002corresponds to a surface from which light exits.

Referring to FIG. 11B, before the mother substrate 2000 is cut, firstand second mother films 2100 and 2200 may be respectively attached tothe first and second surfaces 2001 and 2002 of the mother substrate2000. The first mother film 2100 is adhered to the first surface 2001 ofthe mother substrate 2000 by a first mother pressure sensitive adhesive2300. The second mother film 2200 is adhered to the second surface 2002of the mother substrate 2000 by a second mother pressure sensitiveadhesive 2400. Accordingly, a display mother substrate 2010 is completedor ready for additional processes. The display mother substrate 2010 mayfurther include a mother protective film and a mother support film inaddition to the first and second mother films 2100 and 2200.

The first mother film 2100 may include, for example, polyethyleneterephthalate (PET), polyethylene naphthalate (PEN), polypropylene (PP),polycarbonate (PC), polystyrene (PS), polysulfone (PSul), polyethylene(PE), polyphthalamide (PPA), polyethersulfone (PES), polyarylate (PAR),polycarbonate oxide (PCO), or modified polythenylene oxide (MPPO).

The second mother film 2200 includes a polarizing film to block externallight incident thereto. The polarizing film includes a linear polarizinglayer and a λ/4 retardation layer. The linear polarizing layer may be onthe λ/4 retardation layer. The external light sequentially passesthrough the linear polarizing layer and the λ/4 retardation layer and isreflected by a lower portion (e.g., a cathode of the display panel 100)of the polarizing film. Then, the external light is suppressed since theexternal light does not pass through the linear polarizing layer afterpassing through the λ/4 retardation layer.

Then, as shown in FIG. 11C, a laser beam LZ is irradiated to the displaymother substrate 2010 from the first mother film 2100. The laser beam LZcuts the display mother substrate 2010. In FIGS. 11A to 11C, an area cutby the laser beam LZ is indicated by a dotted line. When the laser beamLZ is irradiated on the dotted line, the display mother substrate 2010may be cut into the display units DU. The laser beam LZ may be, forexample, at least one of a UV laser beam or a CO₂ laser beam.

In addition, the laser beam LZ may be irradiated in a direction from thefirst surface 2001 to the second surface 2002, e.g., the first directionDR1, at the side of the first mother film 2100 of the mother substrate2000.

Accordingly, as shown in FIG. 11D, the display mother substrate 2010 iscut into the display units DU to form a plurality of display devices1000. Each of the display devices 1000 includes the cross-section STdefining the side surface 203 of the first film 200, the side surface103 of the display panel 100, and the side surface 303 of the secondfilm 300. The cross-section ST is inclined and spaced apart from thecenter of the display device 1000 with respect to a normal linedirection of the second surface 102, e.g., the first direction DR1,which sequentially passes through the first film 200, the display panel100, and the second film 300.

When the display mother substrate 2010 is cut, the first and secondmother films 2100 and 2200 and the first and second mother pressuresensitive adhesives 2300 and 2400 are cut into display units DU.

Due to the irradiating process of the laser beam, the first burr BU1 isformed on the lower surface 201 of the first film 200 adjacent to theside surface 203 of the first film 200. The second burr BU2 is formed onthe upper surface 301 of the second film 300 adjacent to the sidesurface 303 of the second film 300. The sizes of the first and secondburrs BU1 and BU2 are changed based on the intensity of laser beam LZwhile the irradiating process of the laser beam LZ is performed. Thehaze area HA is in the upper surface 301 of the second film 300 adjacentto the second burr BU2. The haze area HA has a width depending on theintensity of the laser beam LZ while the irradiating process of thelaser beam LZ is performed.

When the display mother substrate 2010 is cut, the distance between thedummy area DM and the display unit DU increases as the display mothersubstrate 2010 is cut. Since the laser beam LZ is irradiated to thefirst direction DR1 from the first surface 2001, the distance betweenthe dummy area DM and the display unit DU is gradually reduced towardthe first direction DR1.

As described above, when the display mother substrate 2010 is cut byirradiating the laser beam from the first mother film 2100 side, thewidth of the haze area HA in the upper surface 301 of the second film300 is reduced. For example, when the laser beam is irradiated from thefirst mother film 2100 side, the width of the haze area HA is reduced toa greater extent than when the laser beam is irradiated from the secondmother film 2200 side.

FIGS. 12A to 12D are cross-sectional views corresponding to anembodiment of a cutting method when a laser beam LZ1 with an intensityof about 5 W is irradiated six times and a width of haze area. Referringto FIGS. 12A to 12D, the display mother substrate 2010 is not completelycut when the laser beam LZ1 with the intensity of about 5 W isirradiated once, twice, or three times. The display mother substrate2010 is completely cut after irradiating the laser beam LZ1 six times.

When the display mother substrate 2010 is completely cut by irradiatingthe laser beam LZ1 six times, a width of a first haze area HA1 in theupper surface 301 of the second film 300 is about 27 micrometers. Theprocess of irradiating the laser beam several times may be referred toas a multi-pass process.

FIGS. 13A to 13C are cross-sectional views corresponding to anembodiment of a cutting process when a laser beam LZ2 with an intensityof about 10 W is irradiated three times and a width of haze area.Referring to FIGS. 13A to 13C, the display mother substrate 2010 is notcompletely cut when the laser beam LZ2 with the intensity of about 10 Wis irradiated once or twice. The display mother substrate 2010 iscompletely cut after irradiating the laser beam LZ2 three times. Whenthe display mother substrate 2010 is completely cut by irradiating thelaser beam LZ2 three times, the width of a second haze area HA2 in theupper surface 301 of the second film 300 is about 45 micrometers.

FIGS. 14A and 14B are cross-sectional views corresponding to anembodiment of a cutting process when a laser beam LZ3 with an intensityof about 20 W is irradiated two times and a width of haze area.Referring to FIGS. 14A and 14B, the display mother substrate 2010 is notcompletely cut when the laser beam LZ3 with the intensity of about 20 Wis irradiated once. The display mother substrate 2010 is completely cutafter irradiating the laser beam LZ3 twice. When the display mothersubstrate 2010 is completely cut by irradiating the laser beam LZ3twice, the width of a third haze area HA3 in the upper surface 301 ofthe second film 300 is about 63 micrometers.

FIGS. 15A and 15B are cross-sectional views corresponding to anembodiment of a cutting process when a laser beam LZ4 with an intensityof about 30 W is irradiated two times and a width of haze area.Referring to FIGS. 15A and 15B, the display mother substrate 2010 is notcompletely cut when the laser beam LZ4 with the intensity of about 30 Wis irradiated once. The display mother substrate 2010 is completely cutafter irradiating the laser beam LZ4 twice. When the display mothersubstrate 2010 is completely cut by irradiating the laser beam LZ4twice, the width of a fourth haze area HA4 in the upper surface 301 ofthe second film 300 is about 68 micrometers.

As illustrated in FIGS. 12A to 15B, the number of irradiation times ofthe laser beam increases when the intensity of the laser beam reduces.However, the width of the first haze area HA1 in the upper surface 301of the second film 300 after the display mother substrate 2010 is cut isless than the second, third, and fourth haze areas HA2, HA3, and HA4.The size of the first and second burrs BU1 and BU2 reduces as theintensity of the laser beam reduces. The increased distances d1, d2, d3,and d4 between the dummy area DM and the display unit DU reduces as theintensity of the laser beam reduces.

FIGS. 16A and 16B are cross-sectional views of an embodiment of across-sectional structure obtained by irradiating the laser beam twotimes. In this embodiment, the process of cutting the display mothersubstrate 2010 by irradiating the laser beam in FIG. 11C may includeirradiating the laser beam with a first intensity and irradiating thelaser beam with a second intensity as illustrated in FIGS. 16A and 16B.The second intensity may be less than the first intensity, e.g., thesecond intensity may be about 5 W when the first intensity is about 30W.

In one embodiment, irradiating the laser beam with the first intensitymay be performed in a first multi-pass process. Irradiating of the laserbeam with the second intensity may be performed in a second multi-passprocess. The second multi-pass process may be greater than the firstmulti-pass process. For instance, when the first multi-pass processinvolves irradiating the laser beam twice, the second multi-pass processmay involve irradiating the laser beam five times.

As illustrated in FIG. 16A, the first mother film 2100 and the mothersubstrate 2000 may be cut when the laser beam is irradiated at the firstintensity. Accordingly, the first cross-section ST6 may be formed tohave a half-parabolic shape in the display device. Then, when the laserbeam is irradiated to the second mother film 2200 at the secondintensity to cut the second mother film 2200, the display mothersubstrate 2010 is completely cut. Thus, the second cross-section ST7 maybe formed to have a half-parabolic shape in the display device connectedto the first cross-section ST6. Due to the difference in intensity ofthe laser beam, the curvature of the first cross-section ST6 may bedifferent from the curvature of the second cross-section ST7.

FIGS. 17A and 17B are cross-sectional views corresponding to anotherembodiment of a cross-sectional structure obtained by irradiating thelaser beam two times. In this embodiment, cutting the display mothersubstrate 2010 by irradiating the laser beam in FIG. 11C may includeirradiating the laser beam at the first intensity and irradiating thelaser beam at the second intensity as in FIGS. 17A and 17B. The secondintensity may be less than the first intensity, e.g., the secondintensity may be about 10 W when the first intensity is about 30 W.

Irradiating the laser beam with the first intensity may be performed ina first multi-pass process. Irradiating the laser beam with the secondintensity may be performed in a second multi-pass process. The secondmulti-pass process may be greater than the first multi-pass process. Forinstance, when the first multi-pass process involves irradiating thelaser beam twice, the second multi-pass process may involve irradiatingthe laser beam four times.

As shown in FIG. 17A, the first mother film 2100 and the mothersubstrate 2000 may be cut when the laser beam is irradiated at the firstintensity. Accordingly, first and second cross-sections ST8 and ST9 maybe formed in the display device. Then, when the laser beam is irradiatedto the second mother film 2200 at the second intensity to cut the secondmother film 2200, the display mother substrate 2010 is completely cut.Thus, the third and fourth cross-sections ST10 and ST11 may be formed inthe display device.

Due to the difference in intensity of the laser beam, the slope of thefirst cross-section ST8 may be more gentle than the slope of the thirdcross-section ST10. Also, the slope of the second cross-section ST9 maybe more gentle than the slope of the fourth cross-section ST11.

In accordance with one or more of the aforementioned embodiments whenthe display mother substrate is cut by a laser beam irradiated from afirst mother film side, the width of a haze area in an upper surface ofthe second film is reduced. For example, the width of the haze area inthe image display surface of the display device may be greatly reducedcompared to the case where the laser beam irradiated from the secondmother film side. As a result, the bezel width of the display device maybe reduced. In accordance with at least one embodiment, a display deviceis formed to have a haze area with a reduced width.

Example embodiments have been disclosed herein, and although specificterms are employed, they are used and are to be interpreted in a genericand descriptive sense only and not for purpose of limitation. Theembodiments (or portions thereof) may be combined to form additionalembodiments. In some instances, features, characteristics, and/orelements described in connection with a particular embodiment may beused singly or in combination with features, characteristics, and/orelements described in connection with other embodiments unless otherwiseindicated. Accordingly, various changes in form and details may be madewithout departing from the spirit and scope of the embodiments set forthin the claims.

What is claimed is:
 1. A display device, comprising: a display panelincluding a light emitter to emit light including display information, afirst surface, and a second surface opposite to the first surface, thelight to pass through a second surface; a first film on the firstsurface of the display panel; and a second film on the second surface ofthe display panel, wherein the display panel includes a side surfacethat connects the first surface and the second surface, wherein a sidesurface of the second film protrudes outwardly more than a side surfaceof the first film with respect to the side surface of the display panel,and wherein the side surface of the second film is inclined at an anglegreater than about 90 degrees with respect to the second surface.
 2. Thedisplay device as claimed in claim 1, wherein the side surface of thedisplay panel protrudes outwardly more than the side surface of thefirst film.
 3. The display device as claimed in claim 2, wherein theside surface of the display panel and the side surface of the first filmare inclined at an angle less than about 90 degrees with respect to thesecond surface.
 4. The display device as claimed in claim 3, wherein aninclined angle of the side surface of the display panel and the secondsurface is equal to or less than an inclined angle of the side surfaceof the first film and the second surface.
 5. The display device asclaimed in claim 1, further comprising: a first pressure sensitiveadhesive that adheres the first film to the first surface of the displaypanel; and a second pressure sensitive adhesive that adheres the secondfilm to the second surface of the display panel.
 6. The display deviceas claimed in claim 1, wherein: the first film supports the displaypanel, and the second film is a polarizing film.
 7. The display deviceas claimed in claim 1, further including: a protective film thatprotects the second film; a lower support film under the first film; anda third pressure sensitive adhesive that adheres the lower support filmto the first film.
 8. The display device as claimed in claim 1, wherein:a haze area is in an upper surface of the second film adjacent to theside surface of the second film, and the haze area has a width of fromabout 1 micrometer to about 100 micrometers.
 9. The display device asclaimed in claim 1, wherein the light emitter includes an organic lightemitter.
 10. A display device, comprising: a display panel including alight emitter to emit light including display information, a firstsurface, and a second surface opposite to the first surface, the lightto pass through the second surface; a support film on the first surfaceof the display panel; and a polarizing film on the second surface of thedisplay panel, wherein a cross-section corresponding to a side surfaceof the polarizing film, a side surface of the display panel, and a sidesurface of the support film is inclined in a direction away from acenter of the display device with respect to a normal line direction ofthe second surface that sequentially penetrates through the supportfilm, the display panel, and the polarizing film.
 11. The display deviceas claimed in claim 10, wherein the cross-section includes: a firstcross-section corresponding to the side surface of the support film andthe side surface of the display panel; and a second cross-sectioncorresponding to the side surface of the polarizing film, wherein aninclined angle of the first cross-section is different from an inclinedangle of the second cross-section.
 12. The display device as claimed inclaim 11, wherein the inclined angle of the second cross-section isgreater than the inclined angle of the first cross-section.
 13. Thedisplay device as claimed in claim 10, further comprising: a firstpressure sensitive adhesive that adheres the support film to the firstsurface of the display panel; and a second pressure sensitive adhesivethat adheres the polarizing film to the second surface of the displaypanel.
 14. The display device as claimed in claim 10, furthercomprising: a protective film that protects the polarizing film; a lowersupport film under the support film; and a third pressure sensitiveadhesive that adheres the lower support film to the support film. 15.The display device as claimed in claim 10, wherein: a haze area is in anupper surface of the polarizing film adjacent to the side surface of thepolarizing film, and the haze area has a width of from about 1micrometer to about 100 micrometers.
 16. The display device as claimedin claim 10, wherein the light emitter includes an organic lightemitter.
 17. A method for manufacturing a display device, comprising:forming a mother substrate including a plurality of display units, eachof the display units including a plurality of light emitters to emitlight including display information; attaching a first mother film and asecond mother film to a first surface of the mother substrate and asecond surface of the mother substrate, which is opposite to the firstsurface, respectively, to form a display mother substrate; andirradiating a laser beam on the display mother substrate from the firstmother film to cut the display mother substrate in to the light emittersto form the display device, wherein the light passes through the secondsurface.
 18. The method as claimed in claim 17, wherein the laser beamis irradiated in a multi-pass process.
 19. The method as claimed inclaim 17, wherein irradiating the laser beam includes: irradiating thelaser beam with a first intensity; and irradiating the laser beam with asecond intensity less than the first intensity.
 20. The method asclaimed in claim 19, wherein: irradiating the laser beam with the firstintensity is performed in a first multi-pass process, and irradiatingthe laser beam with the second intensity is performed in a secondmulti-pass process, the second multi-pass process greater than the firstmulti-pass process.
 21. The method as claimed in claim 19, wherein: thefirst mother film and the mother substrate are cut by irradiating thelaser beam with the first intensity, and the second mother film is cutby irradiating the laser beam with the second intensity.
 22. The methodas claimed in claim 21, wherein: the first mother film is a supportfilm, and the second mother film is a polarizing film.
 23. The method asclaimed in claim 17, wherein the laser beam is at least one of anultraviolet laser beam or a carbon dioxide laser beam.